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Step7 and WinCC Application at Leeuwkuil Mill in Vereeniging

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Lkm

  1. 1. Technical Summary Siemens TIA Project: Leeuwkuil Mill, Mittal, Vereeniging 2005-2007
  2. 2. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Background <ul><li>Mill rolls special products </li></ul><ul><li>12 Stands </li></ul><ul><li>Plant is a “hybrid” – analog/S5 PLC control: </li></ul><ul><ul><li>Loop control – analog control </li></ul></ul><ul><ul><li>Shear length cutting – PLC control </li></ul></ul><ul><li>Problems with spares </li></ul>
  3. 3. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Requirements <ul><li>Upgrade two existing S5 PLC’s to S7 </li></ul><ul><li>Replace drives with microprocessor-based drives (Siemens SIMOREG) </li></ul><ul><li>Do away with analog control – new PLC functionality </li></ul><ul><li>Configure mill stored setup (“recipe-based”) </li></ul><ul><li>Replace operator desk </li></ul><ul><li>Put in a SCADA (WinCC) and operator panels </li></ul>
  4. 4. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Phase 1 <ul><li>Phase 1 – commissioning Dec 2005/ Jan 2006 </li></ul><ul><li>Replace drives with microprocessor-based drives (Siemens SIMOREG) </li></ul><ul><li>Add Mill PLC (S7) to work in conjunction with existing S5 PLC’s (hardwired communication interface) </li></ul><ul><li>Add SCADA and Multi Panel </li></ul><ul><li>Remove old cables </li></ul>
  5. 5. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Phase 2 <ul><li>Phase 2 – commissioning Dec 2006/ Jan 2007 </li></ul><ul><li>Add Shear PLC (S7) </li></ul><ul><li>Remove S5 PLC’s </li></ul><ul><li>Tune loop controllers without metal in mill (simulated) </li></ul><ul><li>Commission 3 flying shears </li></ul><ul><li>Commission length cutting </li></ul><ul><li>Update WinCC with setup features </li></ul>
  6. 6. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Who/What/Why TIA…? <ul><li>Totally Integrated Automation </li></ul><ul><li>Central Engineering from Simatic Manager of: </li></ul><ul><ul><li>Drives – Drives ES Basic </li></ul></ul><ul><ul><li>SCADA – WinCC </li></ul></ul><ul><ul><li>Panels – WinCC Flexible </li></ul></ul><ul><ul><li>PLC’s </li></ul></ul>
  7. 7. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Central Engineering PLC Drives SCADA/ WinCC Panels
  8. 8. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Easy Access to Drive Trace
  9. 9. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Mill Setup (WinCC User Archives)
  10. 10. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Drive Diagnostics/PLC SCL Decoding
  11. 11. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Profibus Diagnostics
  12. 12. Siemens TIA Upgrade: LKM, Mittal, Vereeniging Value…? <ul><li>Totally Integrated Automation </li></ul><ul><li>Controller tuning for loopers without metal in mill (prevent cobbles) </li></ul><ul><li>Diagnostics </li></ul><ul><ul><li>Profibus N/W </li></ul></ul><ul><ul><li>Drives </li></ul></ul><ul><li>Easy interfacing with S5 ET200U modules – Profibus feature </li></ul><ul><li>WinCC uses Web Client functionality – any machine on the network can access SCADA without extra software/licenses </li></ul>

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